Kargo Master PRO-II KS User manual

ASSEMBLY INSTRUCTIONS
for :
PRO-II KS
• 11253- G Trade Center Drive • Rancho Cordova, CA 95742 •
[phone]
[phone]
®
11_1.1
Parts: 0111-0 & 0113-0

R(8 ea.) M(17 ea.)
I(3 ea.)
1/2" Jam Lock Nut
Thin 3/8" Lock Nut 5/16" Lock Nut
H
O
U
L
(11 ea.) 1/2" SAE Flat Washer
(9 ea.) 1/2" Lock Washer
(15 ea.) 3/8" SAE Flat Washer
(25 ea.) 5/16" Flat Washer
PII-"KS"
0111-0 & 0113-0
F(4 ea.)
3/8" x 3"
Hex Bolt
Z(2 ea.)
3/8" x 2 3/4"
Hex Bolt
W(1 ea.)
3/8" x 2 1/4"
Hex Bolt
P(8 ea.)
1/2" x 1"
Hex Bolt
Q(8 ea.)
5/16" x 3/4"
Carriage Bolt
X(8 ea.)
5/16" x 1 3/4"
Button Head Bolt
G(2 ea.)
1/2" x 2 1/2"
Button Head Bolt
© 2011 KargoMaster-'KS' _11_1.1

Q
U
U
F
U
U
W
U
U
R
R
G
I
J
J
M
O
O
P
P
H
HL
5
8
88
4
3
1
2
• RATCHET WRENCH WITH
1/2", 9/16", & 3/4" SOCKETS
• ADJUSTABLE END WRENCH
• 3/8" DRILL WITH 3/8" DRILL BIT
• CENTER PUNCH AND HAMMER
• 3/4" OPEN END WRENCH
REQUIRED TOOLS
NOT INCLUDED
CAUTION!
• Too much weight will greatly reduce the stability of your
vehicle. Weight carried on an overhead rack will
significantly increase the vehicle's tendency to
overturn. Kargo Master makes no representation or
warranty as to the amount of weight that can be carried
safely by or without damaging the body of your vehicle.
For guidance, we recommend that you consult the
vehicle manufacturer.
• Do not use your rack with the REAR CROSS BAR
removed. The structural integrity will be affected.
• Secure all payloads properly for safe transportation.
ASSEMBLY INSTRUCTIONS
Read all instructions carefully and
follow each step in proper sequence
for ease and speed in assembling
your KARGO-MASTER RACK. See below
for nuts and bolts diagram.
KS
0111-01 & 0113-0
Z
R
7
77
H
P
O
© 2011 KargoMaster-'KS' _11_1.1
GO
O
P
S
i
l
i
c
o
n
e
FOR HIGH RISE CAMPER SHELL APPLICATIONS,
YOU'LL NEED TO PURCHASE SEPARATELY
ACCESSORY LEG KIT # :
31520 - MINI
31530 - FULL SIZE
31540 - 99 - F250/F350
G
O
O
P
X
M
L
L
Z
G
O
O
P

STEP 1
STEP 2
STEP 3
Q
M
L
G
O
O
P
#1 = Cover entire swedge joints with GOOP and
join FRONT and REAR side channels together.
Be sure the connecting plates overlap and bolt
together with bolts Q, washers L and lock nuts M.
#1= Slide REAR BAR on to
REAR SIDE BEAMS
J
#2= Fully insert LOCK PINS
completely to the bend of the pin
KS_11_1.1
GOOP APPLICATION
Apply a healthy air tight bead of goop
around every swaged joint as shown, to
prevent moisture from leaking into and out
of the joint. If this is not done properly, the
inside surface of the tubes can rust and
rusty water can leak out. Maintain this
joint seal throughout the life of your rack.
Swaged joint & holes
Smooth goop at swaged joint & holes
GOOP
GOOP
J
D
06
D
D
04
06
GOOP
G
I
#1 = Cover entire swedged joint surfaces with GOOP.
Slide FRONT CROSS BAR A into FRONT SIDE BEAMS 03 & 05.
#2 = BOLT TOGETHER with TOP (small tube)
& SIDE RAIL (large tube), as shown, using bolt G & nut I.
The allen wrench is included in the package.
05
A

#1= Cover entire swedged joint surfaces with GOOP,
Then insert the swedged end of each leg, rope hooks
facing outward, into the short leg cup.
Repeat this operation for each leg, leaving FRONT
LEGS unbolted.
NOTE: Steps #4 & #5 are more easily completed
with rack turned upside down.
STEP 4
STEP 5
#1= At each end of CENTER CROSS BAR ,
start BOLTS & WASHERS. Be sure to include
both flat and lock WASHERS.
Leave loose enough so that
BOLT shaft can be slid into
the FRONT SLOTTED BRACKET
as shown in #3 below.
H
O
B
P
33
44
//
B
R
U
F
B
B
#2= Bolt REAR LEGS (as shown)
#2= On one side of rack, slide BOLTS & WASHERS
into
FRONT SLOTTED BRACKET as shown in #3 below.
On the other side of the rack, slide the BOLT &
WASHERS into FRONT SLOTTED BRACKET. Bolt
CENTER CROSS BAR
BRACES and LEG together
(snug only).
Returning to the other side
of the rack, bolt the
CENTER CROSS BAR
BRACES
and LEG together (snug only)
#3= With an open end
3/4" wrench, snug the
CENTER CROSS BAR
BOLTS on each side of
the rack.
KS_11_1.1
GOOP
Silicone
GOOP
GOOP
01
01
01
01
Leg Cup
R
U
U
Z
01
NOTE: All 4 LEGS are identical with the
exception of PART 0113-0 (FORD SUPER
DUTY), The FRONT legs are bent twice
and the REAR legs are bent only once.
NOTE: FOR HIGH RISE CAMPER SHELLS, UP TO 6" ABOVE
THE CAB , YOU WILL NEED TO PURCHASE SEPARATELY
ACCESSORY EXTENDED LEG KIT # :
31520 - MINI TRUCK
31530 - FULL SIZE TRUCK
31540 - '99 + F250/F350

STEP 6
STEP 7
H
U
R
W
U
O
33
44
//
C
PC
C
#2= At each end of CROSS BAR
start BOLTS & WASHERS
Slide BOLTS & WASHERS into SLOTTED BRACKETS
on the INSIDE CLAMP PLATES , snug with an open end 3/4" wrench (included in this package)
HO
(MOUNTING PLATES WILL VARY)
Depending on the make and
model of truck.
7a
P
KS_11_1.1
P
O
H
01
The front Mounting Plates have Support Arms. Slide one Arm
into the other and attach this assembly loosely to the front
legs of the rack using bolts P, lock washers O , and flat
washers H. Attach rear Mounting Plates loosely to legs using
bolts P, lock washers O & flat washers H.

L
L
X
W
U
R
M
L
X
INSIDE BED WALL
REAR VIEW OF TRUCK
©2011 KARGO MASTER --KS_11_1.1
Outside of
Truck Bed
P
O
H
THAT'S IT!
You're ready to use and enjoy your
KARGO MASTER TRUCK RACK!
BULKHEAD
THROUGH
BOLT HOLE
3/8"
3" 8
CAMPER SHELL
(MOUNTING PLATES WILL VARY DEPENDING
ON MAKE AND MODEL OF TRUCK)
#2 = Position the rack on the truck as far forward as possible, with Mounting Plate tongue over the front bulkhead of the
truck bed. Center the rack left to right on truck bed. Slide the front Mount Plates apart so that they are flush against
opposite sides of the truck bed. Measure the inside dimension of the Mount Plates just above the Support Bar, and the
outside diminsion of the ridges (if any) on the bottom of your shell. It may be necessary to notch this ridge to avoid
interference with the Mount Plates. Or, you may want to notch the ridge front and back so that the Mount Plates can be slid
in towards the center of the truck to minimize overhang.
#4 = Remove Rack from the truck, and unbolt the Mounting Plates. Punch hole centers in the locations that you have
marked and drill 3/8" holes in the Mount Plates and the inner Support Arm.
#5 = Bolt the Support Arms together using bolt W , Flat washer U, and lock nut R.
#6 = Set the Mount Plates back on the truck, in exactly the same
location that they were before. Make certain that the Mount Plate is
square with the bed rail and dead horizontal. We recommend that you
clamp each foot plate in position before drilling through the truck's bed
rail. CHECK TWICE - DRILL ONCE!
#7 = Apply adhesive foam tape (NOT INCLUDED) to seal the
gaps between the footplates and camper shell along the bed
rail and bulk head. Attach the camper shell to the truck. Place
the rack on the Mount Plates and center. Adjust each rear leg
slightly side to side to ensure that the lock pins in the
removable rear bar slide in and out easily.
Tighten up ALL bolts and...
#1 = Remove your camper shell from truck. Note wheather or not there is
a ridge on the bottom of your shell.
#3 = With the Mount Plates in their final position, locate and mark two optimal bolt hole locations on the top of each Mount
Plate. The bolts should be located as far apart as possible, with clear access to the bolt and nut underneath the truck's bed
rail. If the inside of your truckbed has a double wall and it is not possible to locate a bolt on the Mounting Plate near the leg,
we recommend using our accessory STAKE POCKET "T" BOLTS to provide an additional attachment point. With the
Front Mount Plates in thier final location, mark the through bolt hole in the inner Support Arm.
STEP 8
KS_11_1.1

DON'T OVERLOAD YOUR VEHICLE!
100" = X3 lbs.
35" = x1 lbs.
@
@
O
V
E
R
T
U
R
N
F
O
R
C
E
LBS.
LBS.
WEIGHT CARRIED ABOVE THE FLOOR OF THE TRUCK BED (E.G. ON AN OVERHEAD TRUCK RACK)
WILL SIGNIFICANTLY INCREASE THE VEHICLE'S TENDENCY TO OVERTURN. ALWAYS KEEP
HEAVY LOADS EVENLY DISTRIBUTED AND AS LOW AS POSSIBLE. IT IS IMPORTANT TO NOTE THAT
THE KARGO MASTER RACK LOAD BEARING CAPACITY OF 1700 LBS. MAY BE GREATER THAN YOUR
TRUCK'S GAWR OR GVWR CAPACITY, AND IS PROBABLY GREATER THAN THE WEIGHT THAT CAN BE
SAFELY CARRIED OVERHEAD.
For TECHNICAL SUPPORT Call:
1-800-343-7486
HOURS: Monday- Friday 8:00 A.M. to 4:30 P.M. (PACIFIC)
®